Document 5L5xrrX6d4Eg364aQB6Mdv2Lz

FILE NAME: Ford (FD) DATE: 1970-1983 DOC#: FD149 DOCUMENT DESCRIPTION: Industry Warning Information with 1983 Report - Industrial Hygiene Audit of Ohio Truck Plant WARNINGS IN SHOP MANUALS (A sbestos Cases) The follow in g is a r e view 1982 o f Ford Motor Company c a r . anJ , ^ r ^ u^ F d ir e c t e d to any w arnings m th e manuals m an u als from 1950 to_ n9 b J e r e p a i r s . S in c e much o f la n g u a g e a b o u t a s b e s t o s d u s t i to y e a r and w it h in t h e v a r io u s shop manuals is rep ea ted from year e a r /s a m p le s o f each type o f warning (or lack is s u e d in any giv en y as e x h ib its A through I . Reference w i l l be t h e r e o f ) a r e a t ta c h e d e x h i b i t and th e lan gu age c o n ta in e d th e r e - made to a p a r t ic u la r 1970 1974 1975 1975/76 1977 1977 1978 1978 1979 19 80 1980 19 80 19 80 19 80 1981 1981 1981 1981 1981 Car Car Car ' Car Car Truck Car Truck Car L ig h t Truck M edium/Heavy Truck Volume 1 Volume 1 Volume 1 Volume 1 Volume 1 Volume 1 Volume 1 Volume 1 Volume 1 3CE* BCE F airm ont/Zephyr T -B ird /C ou gar BCE P in to/B ob cat ^ M ustang/C apri . G ranada/M onarch/ V ersa illes BCE Ford/M ercury L incoln C o n tin en ta l/ C o n t in e n t a l/M a r k V I BCE L incoln E scort/L ynx BCE BCE L ig h t Truck M edium/Heavy Truck BCE BCE C ourier BCE 12-01-08 A 12-01-12 A 12-01-23 A 12-01-24 A 12-01-29 B 12-01-22 C 12-01-32 D 12-01-22 C 12-01-31 D 12-01-20 E 12-01-20 E 12-01-22 D 12-01-23 D 12-01-20 E 12-01-22 E 12-01-27 F 12-01-18 E 12-01-24 E 12-01-6 A 005222 PBODUCtU BY F O R D warnings in shop manuals page 2 1982 1982 1982 1982 1982 1982 Lincoln-Town/M ark VI Ford/Mercury Lincoln Continental 1-B ird/X R _ 7 Fairmont/Zepkyt Granada/Cougar Mustang/Capri Escort/Lynx L igh t Truck Hedium/Truck Courier BCE BCE BCE BCE BCE BCE II I BCE - B o d y , C h a s s i s , E l a c h r i o a i 12-01-22 E 12-01-25 E 12-01-25 I 12-01- H 12-10-6 G 12-01-05 A 005223 pr o d u c e d by FO-C A 12- 01-08 General Brake Service 12- 01-08 " bi inspected [or wear or damage: 9. On floating caliper type disc brakes, the caliper assembly must te removed Irom the spindle prior to re- --movak of the shoe and lining u x m - replacement of the retracting and hold-down sprm2S is strongly recorn- . mended Overheated springs lose their pull and could cause the new lining to wear prematurely, if they are not re placed. If (he brake drums are heat " |0. On floating caliper type disc brakes the calipers must not be inter changed from one side to the other. When the-caliper is installed on i proper anchor plate and spindle, the bleeder screw will point to the rear of .the vehicle. If a caliper is installed on the wrone side of the vehicle, it is not possible to bleed the system properly 11. Do not attempt to clean ' restore oil or grease soaked brake lin- inzs. When contaminated linings ar found, brake linings must be replace spotted, indicating a overheated con- dltion. they should be replaced. 5. If the vehicle has 30.000 or more miles of operation on the brake linines or signs of overheating are pres ent When refining brakes, the wheel cylinders should be disassembled and inspected for wear and entrance of dirt into the cylinder. The cylinder cups should be replaced, thus avoiding ofuture problems. 6. Inspect all other brake parts and replace any that are worn or dam- in complete axle sets.- *^7^ Inspect the brake drum and. if necessary, refmlsh. Refer to art DRUM BRAKES 12-02 tor refinishing. ' . BRAKE BOOSTER ' : ' l.' Remove the wheel from the drum, and remove the drum -as .o u.it- Check the booster operation as lined in Part 12-02. ' . 2.. Brush all-dust from the backinngiTl plates ' and interior of the brakke,e j noted in Part 12-01. Power Brake Functional Test. If the brake booster is damaecd or inoperative replace U r dT i 't n p e c t the brake shoes for ex-" cessive lining wear or shoe damage If with' a new booster. The brake boost er is serviced only as an assemb y. the.lining is worn within 1/3- mch of .. : HYDRAULIC UNES . ' ' the rivet heads 'or if the shoes are damaged, they must ' . Steel tubing is used throughout the place., any, lining that had -been eon.. .. brake system with the except.on o laminated with oil.' grease or brake . ' the flexible hoses at the- front wheels fluid. Replace lining in axle sets. and at.th e rear axle housing, brake Prior to replacement of lining, `be drum diameter should be checked to lube connection. . Alw-avs bleed the applicable pri determine if oversize linings must be mary 0; secondary brake system after '" ^ 'C h e c k the condition of brake shoes, retracting springs, bold-down springs, and drum for signs of o* erheating. If the shoes have a shght primary or secondary brake system hose or line replacement. Centralize the pressure differential valve after bleeding the system. blue coloring- indicating overheating. BRAKETUBING ' If a section of the brake tubing be comes damaged, the entire section should be replaced with tubing of the same type. size, shape and length, Copper tubing should not be used in a hydraulic system. When bending brake tubing to fit underbody or rear axle contours, be careful not to kink or crack the tube. : ` All brake tubing should be double flared properly to provide good leak proof connections. Clean the brake tubing by flushing w,th clean brake fluid before installation. When connecting a lube to a hose, tube connector, or brake cylinder, liehten the lube fitting nut to spea- fied torque with Milbar Tool 1112- |44 or equivalent. . . . .- BRAKE HOSE . A flexible brake hose should be re - placed if it shows signs of softening, ' cracking, or other damage. When installing a new front brake hose, position the hose to avoid conlacl with other chassis parts. Place, a new copper gasket over the hose fit ting and thread the hose assembly into the front wheel cylinder. Engage ; ibe opposite end of the hose to the bracket on the frame. Install the horseshoe-type retaining clip, and con nect the tube to the hose with the tube fitting nut. A rear brake hose should be in stalled so that it does not touch the roufRer outlet pipe or shock absorber. Thread the hose into the rear brake tube connector. Engage the front end ' of the hose to the bracket on the frame. Install the horseshoe-type re taining dip. and connect the tube to the hose with the lube fitting nut. 005224 General Hydraulic Brake S e r v i 12-01-29 & Clean all parts in clean isopropyl alcohol, and inspect the parts for chipping. excessive wear or damage. W t o using a master =yl>"<i repmr , install all the parts supplied. 3. Install the primary piston assembly in the master cylinder bore. 'i. D epress the prim ary piston and install the snap nng in the cylinder 3. bInosrtealglrtohoevpe.ush r^. b o o t a^re^n. or 3 Install the cover and gasket on the ' master cylinder and secure the cover into position with the retainer. PUm~t 1 Be sure that all recesses, openings and ' internal passages are open and clean. Place lII parts on a clean pan or on the push rod. if so equipped. Ins aU the push rod assembly into he . primary piston. M ake sure the Snap INC g. the master cylinder bore for ii n u oi etching, pitting, scoring or J k If necessary to hone the master cylinder bore to repair damage, do not exceed allow able hone specifications. . . re ta in e r is properly seated and holding the push rod securely. 6. Position the inner end of the push rod boot (if so equipped) in the master cylinder body retaining groove. 7 Install the secondary piston stop bolt. ' if used, with an 0-nng if screw is on bottom outside of master cylinder l^ E d p all parts except the m aster ' cyUnder body in clean brake fluid (ESA-M 6C2J-A) Ford Part No. C6AZ-1954Z-A or DOT-3 equ.valenL Z C arefully insert the com plete secondary piston and return sp n n 8 assembly in the mas-er cylinder bore casting. 9. L n stall th e bleed screw (if so eq uipped). In stall the gasket (diaphragm) in the master cylinder filler cover. Position the gasket as shown in Fig. 23. Make sure the gasket la securely seated. HUTJ-C FIG. 2d Removing Snap Ring Typicol " (Fiy, 23). 005225 CLEANING AND INSPECTION F ront wheel bearing end play DISC BRAKES c ritic a l and m ust be w ithin ^ 1. Remove the wheel and tire Jrom the _ . hub in d rotor." . - r Inspect brake shoes and lining for ' w a r. If the lining is worn to within -i/g inch of the fhoe. replace all ( ) shoe and linin', assenhhes (complete . axleset)-or `rout or rear wheels as - `^ u r r S ^ h i e l e is centered on the hoist before servicing any Iront end components, to'avoid banding or damaging the rotor splash shield on full right or .left wheel turns. . Riding f the brake peoal (common on left-foot applications) must be 3' Y u S l l ' check the K ** . ' caliper housing is leaking, it should bc replaced. If a seal is Waking. ' eJiper must be disassembled andnew . je a h in stailed. If a piston a a d NT avoided during vehicle peraOtu 7. The wheel and tire must be removed -.-.parmtely from the brake ro . ualiir drum brakes where the wheel, ore awd-Irum can be removed as a - the bore, a new caliper hon.ung Do not attempt tc dean i o n * S t e i P t 12-20 f o r * / rake . mtor resurfacing procedure. . oc grease-soaked brake UmnP- ^ b e n cootaminated linings are found, brake lim g s must be. replaced -us cora pete sets. Prior to replacement of lining, the drum diameter should be checked ... to'delerm tne th at-th e brake-drum ' braking surface diam eter is within specification. If the braking surface diameter exceeds specification, the drum roust be replaced. i, Check the condition of brake shoes, retracting spring*, hold-down sp rin g s, and d ru m for sign. of overheating. If the shoes have a Slight blue coloring, indicating overheating, the retracting and hoid-down springs should be replaced. Overheated springs lose their pull and could cause the new lining to wear prcmaturtl.. if not replaced. If the brake drums are heat spotted, indicating an overheated condition, they should be replaced. 5. Inspect all other brake parts and replace any th a t *.e r DISC BRAKE SER'OCf' . . . : i PRECAUTIONS ^ ` ^ I I a r o s e tJ any other foreign matenni must oe kep off the linings s^riaeea ` of the rotor, andd. externalt suurfrarcaess o- f axle sets. /.'-dxamagedu. -r Inspect the b rak e drum and. it -ORUM BRAKES ` " nccessahy. refinish. The max,mum inside braking surface dtametor- is . ' \ . Remove the wheel from " >e drum. . shown on each brake drum tFig. an 3 remove the dium as outlined in ___ ^ ^ If the maximum inside braking surface diameter shown on the drum is exceeded e ith e r by w ear or ixsemuues, avuiu -- -------- . I brake rotor and nit king or scratching of brake linings. 2. If caliper piston is removed for any ' reason, the piston seal must-be 3 D uringcm oval and installation of a . - wheel assembly, exercise care not to ! interfere with and damage the caliper ' splash shield or the bleeder screw rerinishing. th e drum must be . replaced. Refer to Part 12-02 for the brake drums. . Inspect the brake shoes for rtfmishing. _ i. lining wear or shoe damage. If foe lining is worn within 1/32 inch riv e t h ead s or if th e shoes are BRAKE BOOSTER Check the boler opOTiwa oied dam aged, they m ust be P u d . . under Power Brake Functional Test 1 Replace any lining that had been cortm inil with oil. grease or the b rake b o o ste r is dam l S= inoperative, replace .t w.ih a new booster. brake fluid. Replace lining m axle fining. a / . - J ? S to , p r o d u c e d by FOPO f '. r-. t;--.i'-.Y -Y f : :; -F--.-. Vl it 005226 -a * r-- Genera! Hydraulic Brake Service" --- - '.-S. -Remove the line and inspect the Hare. for-cracks or poor flare form. If the flare ts not correct, cut it off and ' ', repeat the process, . : ' The finished flare must be square with the line, free of cracks and have . a smooth mating surface to ensure a.. leakproof, connection. - Flaring a Lina IFlaring-S ar Type) . ' Refer to Figs. 15 and 17. * i Cut' o/T and straighten the required ; . .' length of line. (A line cutting tool will ,, . . . simplify making a clean and square ' ' " cut). ' . . ' * 2. Square off the ends of the line with a ' .file, and chamfer the end of the Line " ' "' to be flared. ' 3 ' Insert the line through its appropriate ' ribbed hole in the bar assembly, until . - -the end of the line sticks out about as . far as the thickness of the.adaptor above the bar. or even with the bar.depending on the tool used.- -- 4. Fit the adaptor onto ihe line and slide the bar mto the yoke. Lock the bar in . ' position with the line beneath the yoke screw. _ .. ' 5 . ' Form the single flare by tightening the yoke screw securely. 6. Release the screw and remove the adaptor. ' 7. Form the double flare by tighenmg the yoke screw again, with second . adaptor fitted, depending on.the tod used. 8. Release the screw bar, and flared line. ' Inspect the flare for cracks or poor flare form, and repeat the process if the flare is not correct. .. ?. Repeat S te p s.3 th ro u g h ji at the ' opposite wheel cylinder.- 12-0 i Tl FIG. 17 Line Flaring (Flaring Bor ... ... ' Type) BRAKE HOSE . . . ; Replace a flexible brake hose if shows signs of softening, cractm i a other damage. . When installing a new brake hox. position the hose to avoid contact wiri- other vehicle parts. . .. . REMOVAL AND INSTALLATION ; ' BRAKE DRUM . . . . - . All V ehicles th ru 9 0 0 0 S eries Use the following service procedures for both hydraulic and' air brake. Since the F-100 thru F-350, E-100-E-350 and ' .'.Bronco rear drums, and the P-5Q0 (front and rear) "procedures apply to hydraulic ' -brake only, they are covered m Part 12` 4. Remove th e front w heel-to-hub retain in g n u ts (or rim a n d lire attaching nuts). Remove the wheel ..(or rim and tire) from the hub and drum. ' . 1 Remove the brakg dntm retainers and- ,. "'attaching bolts,- screws- or bolts-and - . nuts. " ' , 6; Remove the brake drum .'from .tfle ... 02*.-.../....a -. ' (FRONT b r a k e d r u m " ` 1 Raise the vehicle until the tire dears ' ' the floor and remove the wheel and tire from the hub. Loosen the brake shoe adjusting screw until the shoes no longer touch the brake drum. Remove the grease cap and the gasket (if equipped) from the hub. 2_ On vehicles with 9,000 lb front axles and hydraulic brakes, remove the ta in u t, locking ring, dimpled washer and adjusting nut. On all other axles, remove the cotter pin. adjusting nut and flat washer from the spindle. 3 Remove the outer bearing cone and ' roller assembly. Pull th eh u b and drum assembly off the whed spindle. "huh.' . . .- ' ' .. '7 . Check the drum for damage or wear. and repair or replace if necessary. If a new drum will be installed, be sure to remove the protective coating with ' degreaser. . . Install new grease retainer seats whenever a wheel and hub is removed. g. Place the brake drum to the hub and install the retainers and retaining _ .bolts, screws, or bolts and nuts. 9. Install the hub and drum on the whed spindle. Keep the hub centered on the spindle to prevent damage to the grease retainer or the spindle threads. 10. On vehicles with 9,000 lb front axles and hydraulic brakes install the outer bearing cone and roller assembly. inJ the'bearing adjusting nut. On ill other axles, install the outer beann| . _ cone and roller and fiat washer on the ' spindle. Install the adjusting nut. i f. Install the wheel and tire on the hub .' Then install the clamps (if applicable)' . and the whed s t u d . n u t s . , . , > y 12. While.rotating the wheel, tighten the adjusting nut to specification. Adjust whed bearings as described in Group 11. ' ' 13. On vehicles with 9000 lb front axle and hydraulic brakes, install the dimpled washer with the dtmpit indexed in one of the holes in the adjusting nut. Install the locking ring lock nut and tighten to specification. Bend the locking ring over a fiat of the lock nut. ' \ " 14. Install the gasket (if equipped) and the grease cap. and tighten the * stud nuts to specification. Instal hub cao (r equipped), and adjust brakes is described in this Part- OVERHAUL An industrial type vacuum cleaner in place of compressed air. is recommended to remove any dust and din present on brake linings, pads, rotors and drums ect, when performing wheel brake repairs. Also, any m a c h i n i n g done on brake linings or pads should be done using properly exhaust ventilated equipment. f brake d r u m refin ish in g E-100-- E-350, F-100-- F-350, U-100 Minor scores on a brake drum can be removed with fine emery cloth, provided the emery is thoroughly cleaned off the - drum after the operation. A badly scored, rough, or out-of round drum should be ground or turned ^ on a drum lathe. Do not remove T more material from the drum h* necessary to provide a smooth the brake shoe contact. Brake ^ maximum braking surface t Shown on each brake drum Brake drums which exceed the m ^ braking surface diameter shown [ j n . ->-- " " S /o A u J / l . o > - 2. 2. _____ _ PRODUCED b y fo r d ..-.I- r. General Hydraulic Broke J ^ n - 01-33 1 2 -0 1 -3 2 ' n o t re p la c e d . If th e b ro k e d ru m s are h e a t M kd. ' .calip e r h o u sin g is re q u ire d - R e fe r to P a r t 1 2 -2 0 fo r d isc b r a k e ro resurfacing procedure- . . . . ' D,SC BRAKE SERVICE PRECAUTIONS i. pp ooitTt eeda ,, imnudiikc "a t"i"n3g an o~ v e r h e a t e d co n d itio n , th e y sh. o' ul.d, ,b e _re_pIl_a_c_eAd . 5 . Inspect all other brake parts and rep lace any that ' a re worn or d a m a g e d . . ' ' Inspect the b rak e drum and if n ecessary refinish. 6. The maximum inside broking surface d ,am , ,r J, sh o w n on e a c h b ra k e drum (F ig . 3 3 ). If th, 1 - G rease or any : " w s r h ; h u b j u ^ ;;::^ ^ external s ^ - js maximum inside braking surface d iam e ter shown on the drum is exceeded either by w ear ar retm.sh.ng. the drum must be replaced. Refer to P art 12-02 Itor d efo rm atio n of " he brake rotor and nicking or refinishing brake booster . ' .2 .. for any rs a io n ' the _ . piston seal must be replaced. r t ,, ,, J InitC lotion Of 0 w n e c * 3. During r e m o v a l a n d | ter*ere wirh and Check the booster ooeration os noted under Power - y - d -w including the check v alv e. b r i ,, 9 .n d ploy 1. ` " ' i ' " 1 " d 4. .. .. s- sben.disng .orWdamagxing stheirortorasp s M - " right or left w heel turns- . .f f th _ b rak e pedal (common on left-foot . ' 6:- Riding f. , he. e QVOid e d d u rin g v e h ic le brake tubing . p>*"?' ;t: b; f j J S t f S B f t S f r * % t J 0^. , u,n ' l !y p e t b e u se d in a h y d ra u lic s y s te m . Wnen l h ^ - d n broke tubing to fit u n derbody or rear axle b" S b . . . H * " ` ra` k '"b" hydraulic lines 005227 C C S * * ' z r i b: r t^ , ' x r, r t " . " D ' ^ ^ ^ ^ ^ ^ ^ "^ h e n 'c o ^ ta 'm h ic ^ e d ^ lin in g s ` . . " X bj i S i 11. r `.'.bV ' p " p lh . ,, ,, ,, lU .b l. P.i .ry ' the system. - ......... . ' A . t a t . H .M ., . l f b ' d r uU mM BRAKE5 . ,1 _ tK_ w h e e | from the drum, a n a rem ove the Remove th e * neel. Ir , - . 02 '1 drum a s o u tlin ed in P art 12 0 4 . I " f iS l b ,o i= " "ij b= ,or' l ' U i i s . To, i m - * - ^C 3. Inspect th e b ro k e l^ V n n n g 'h w orn'^"thin 1 /3 2 they m ust be rep la c e d been contam .nated R eplace lining .n lining, the drum * Replace^ny I ^ ^ , 9 rep | Qcem ent of P j *, J checkE d to b a tin g surface equivalent. - bra ke hose . A flexible brake hose should b e re P 'a e ' J ' ` ^ sigi s of softening, cracking, or oth er dam age v/hen o - > S ^ j= f s s J i = Vehicles except P c i r f r t n g ^ a n ^ "hr "a d * ^ e " h o s * g a sk e t over the hose t thng d e f Qf e a |,p .r . assem bly into the front wheel cy a copper rSx# s i r .. F g airm o asket nt/Zephyr an d is reu front sable. bE" e 9 J " e*h= 9 opposite end of the ^ whi)e $tfipe on hose to the bracket on r twisting. Install th the hose should show no evj ^ CQnnec, )h<j tubo ,0 horseshoe-type retaining clip. the hose with the tube fitting nut. J P R O D U C E D BY r-ORO General Hydraulk l2-01-2g OVERHAUL fluid or oil c o n t a m i n a t i o n t h a t is causing a brake ' S replace all four shoe and lining assemblies. 3 . To ` heckenM p 1f 8 .m =l "I di ,t * ' 1 to*uodTM b'ok" . ,. ,,jv a t o r to the spindle so the stylus A. Clamp a dia I a a ro x -irnatcly one inch from rh 6500161 or an =quiva , either blowing off with on should no be rem0 wd;,h a stan d ard industrial vacuum air gun or vacuuming > h a ia rd from b reath in g m c le a n e r b e c a u s e 0 ,h e " l " Als0> ony m achin.ng done " ' r BS t e fh e " tor and take an indicate OUtMnea 9 |f Me reading ex c e e d s ,252m m (0.010 re a d in g , it tne -(u:n a six incn raaius an inch! 1 0 ' * * S ,ol. asb esto s f U5t ma,,Yr o a d s l s h a u id b e 0dnone using properly \ rotor, fmh e 'hilJi i " 83 ,. b ra k e ro tomrs",' ' b' s S ir 2 s *v s w hen ro-su ig re.f*,nish the disc brake oMrs V o l t o i the m anufacturers instructions.! L BRAKE DRUM REFINISHING No more Athnann -5508Imm [' 0.02e0achincshu)rfoofcem(aAterQinadl y h, ,W ck n ... l=H. b . l . - ,h. A b a d ly scored' , r ^ 90 'd u m lath e. (Refer to the lath e . be gro u n d or turned o n ru femove Qny more M anufacturers i n TM ,, " . ,, ,, a r y to provide a m aterial from smooth surface for he b ^ shoe c o n tac t. Broke drum ^ 0n each m aximum brt^ .' g , 3, Brake drums which excee , brake drum I -9- 3 { B a *,am eter shown on the brake maxim um braking *u ' t a " or ,, fin is h in g . must, be -d ru m , e ith e r th ro u g h , 1 broking s u rfa c e d ia m e te r rep laced . The ^ o x .m u m b ra^ ^ ^ drum (F,g. . .specification which i . Q60 inch) machining cut " i 3 i; allows for a 1.52m t d]arneier plus .762mm over the ^ . " Z ea b efo re reaching-he. drum discard diameter. . . ... - -. . n u -n riW ; .r l -f f " chi 3, 7V,,,|1.JS INCMl .0 OO --Q.SOfin-n. lOXOT'NCHI MINIMUM 0 V S - S thickness "39mm 10.98 lf*CHt O00 Q.kO ^em 10 0 5 0 INCH m in im u mTWOVtCEKRFAiELSLS 70.44mm- 11.120 INCH iaovF .22MS0UmX m Al.NxO1,F*M 0 30-22" 11.190 1NCHI* * 0Q.3000^**mKUDONCH1 1 T m,NMU*ThovcexbmalXlS--* a.4nn. 11.1 F-100 4800/*200 C W lR niTH POWER RAKES -B_isoI**21 r-UOl** '2^ cwi* H200S.IC UAXtMU OiAOETEB Hie*' ,, Drum M aximum Inside FIG. 13 Surface Diameter. M arking Brakmg Sur , 00_ E_350, Bronco, and F Location-- c-iuu TOO--F-350 front disc brakes ^ 5n Part 1. Remove the ^ ' ^ M l ig h M ond H e a v y D u ty -- 12-24 Disc Brakes u y Sliding C aliper. b ra k e Kning> |f the S 2. Mlineinagsutrheictkhneestshiactknoenssy ^ ^ ,be assem bly is less the backing plate *' - " T i f nC,S' IC/-, " - 0 - .. . . ,b ' k' . ^ , rL. . s t c F,G. 14 Disc Brake Rotor Service Umit. The finished braking s u r f * 'h?0 o o k S b be i c and parallel (0.003 la te ra l nmout must the surface fmn b- - 80 W h e n the rutiout c^heck is Q .'w h l( bearings a* d e lf" F ro n t ( e x c e p t Fron H u b s an d B e" n " 9 nt bearing failure. W h e e l Drive) Pr RemQye m;nor scote 5. Check the rotor ,or ra.or is excessive^ ^ X o r t p U t h e t o t a r if necessary- vith scored, j f4, PRODUCED BY FORD 005229 general hydraulic brake service 12-01-27 uohiHe is centered on hoist before ser S Be surs , . encj components, to avoid ben- So " ro,or 5Blash snie,d SS5 or leIt wOeel turns. , hrstWp oedal (common on left-front ap J;S o n s) must be avoided auring vehicle operation. , , _ _ j tira must be removed separately h TMW e ebrake rotor, unlike drum brakes where i r w p e e i t and drum can be removed as a 4. Check condition of brake shoes, retracting spr ing holddown springs, and drum for signs of overheating. If shoes have a slight blue colorinn indicating overheating, retracting and hold down springs should be replaced. Overheated sorings lose their pull and could cause new Un ion to wear prematurely, if not replaced, brake drums are heat spotted, indicating an overheated condition, they should be replaced. 5. Refer to part 11-15, for hub nut tightening pro cedure. unit. n nn( attempt to clean or restore oil or grease- 4 ^ win brake linings. When contaminated LnM,, f a?e lo u n d b L i, lining must be replaced S o m i t e i . sets and the rotor waking sur- (aces wiped clean. 9. Do not lubricate caliper slide pins. Brake Booster rh p e k booster operation as noted under Power Brake Functional Tesh It wake - .e lu d in g th e check valve. . * " Vi installed with bleed screw s in .J . 2 'u p a TM p iS o n tor proper bleeding bl air ~T` " Irom brake system. Drum Brakes ..... ,r-' ... ' v Remove wheel, tire and drum assem ^l^Irom , : spindle. . ; '. - i ' t * Brake Tubing ' ! if a section of brake tubing becomes damaged, V 8 0 `me8 t y 'p e 0 s C - S l e n g l " C o p p e r tub- :-the s a m%tyPe *bS' ^ eSd in a h y d ra u lic s y s te m . W hen . K i n g b S a iuking - > .'careful not to kink or crack tube. conioum, W - - . -. Hydraulic Lines brake drums. . . - WARNING- Never inhalii dust from brake linings J is to T d u s t when - h a l e d can be m.unous to htallh DO not blow out dust with an air line, a - Tieuum cleaner equipped for this r.g should be carefully used to remove ary t o t . Any dust should be contained in a sealed bag fo^ diiposal. ; hoses at the front and rear- wheels. . alw ays bleed applicable primary ^ econHdr^ n r r , , S f S a ^ m a n r dS S pmLsure dlllerenlial v a lv . altar bleeding system. 3. Inspect brake shoes for e BaSiv* JJ" or shoe damage. If lining is damaged or worn within 1/32 Inch of the rivet heads on Inas or within 0.060 inch of the shoe on bop" linings, they must replaced Replace any Uning that has been contaminated with oil. grease o . brake fluid. Replace lining in axle sets,^Pr replacement of lining, drum diame hrakina checked to determine that brake drum braking . . surface diameter is within sPec'f,c^ n =: braking surface diameter exceeds p . lion, drum must be replaced. . . . bfaketubtngd^}y* flushing wttb clean brake t.utd before installation. _ . ..... ' W ,,en connecting a tu b * J ; ; ' S acT ite d torg'ue ith ?be DSU.-600.A inch-pound torque wrench. . . . - * I \ - - ** ' ` . Iff-1 S ^ y tft'i-'J 1 1 - <r' X 7 P R O D U C E D BY FO R D 1-10-6 Droite urum I A- I V-Q 6 i e MOval AND i n sta ll at ion / ,,,fewW W'-> " ^ h yhdydrarauulliicc bbrraakkeess. Wi* ' " : "* *1 W.. eVe r In_ hua_lie. jd u. ics t* ffrroomm bb rr aa kk ee lliinn iinn gg ss.. F U S I N G : N ^ h e n ,n h a l e d cQn b a in ju rio u s to A ^ 10* nu*' oyt d u st w ith an air line. A ~ " h- D; eann lr ^ e q u ip p e d fo r this p u r p o s e , b ru sh I ,, " / b e carefu lly used to rem o v e any 7 b' ^ dU p*Ql- ^ SPOKE WHEELS in 0 7 . the vehicle until the tire clears the floor and *,, o i l sa fe ty sta n d s. R em ove the Hre a n d run Remove the cost spoke w heel and drum assem bly Irom the front or rear ax le. Remove the drum from the cast spoke wheel by 3 .moving the nuts, bolts and w ashers. 4 ' * Cfcf 7 ,, T , t p" S J !3 w - wi.h = 9 -- . MOTE- Replace the drum with the sam e type and vc'-'r i a H u r e to d a so w ill a f f e c t v e h ic l e . performance. Replace cast drums with e a s < ^ m R Replace centrifuse drum s only w ith .vMfrvms. . - ..- =a - ' :-`V krl> Nation ,. . v... ... '.''- I . Assemble the drum to the cast spake: spider Tighten the'nuts to 299-352 N-m [220-260 ft-lbs). ...-c ...* * 2. Assemble the cast spake spider and drum assembly ' to the front or rear axle. Adjust the wheel bearings and the axle shaft installation, if n ecessary, per the a p p ro p ria te Section in G roup 1 1, 3. Install the tire a n d wheel assem bly on the cast ' spoke wheel. Refer to Section 11-01, W heels, Rims and Tires for the procedure. 4. Tighten the front an d rear w heel clam ps to 299-352 N -m [220-260 ft-lbs). DISC WHEELS-- OUTBOARD MOUNTED DRUMS 005230 Removal 1 Raise the vehicle until the tire clears the floor ond ` install safety stands. Remove the nuts retaining the tire and w heel assem bly to the hub (Fig. 6). 2. Remove the drum from the hub. 3 Check the drum for dam age or w ear and repair or ' rep lace as necessary. If a new drum ,s installed, oe sure to rem o v e the p ro te c tiv e c o a tin g with degreaser. ' NOTE: R eplace drums with drums of the sam e type. ' F a ilu re 'to do so will a ff e c t vehicle track and perform ance. Replace cost drums only with cast d ru m s. R e p la c e c e n tr if u s e drum s only^ w ith^ centrifuse drums. -r Check w heel grease seal's for le a k a g e . If the hub removed;from-the axle, Install new wheel grease ' ' seals. - ' ' ' .............. 0 IN* ^T0. & Braka Drum Mountings ; - x .- ,-i..r. ' . '>i v.. u ' . . vans-s* . - y ;; 4 r ' . n . -- 7 Qr~C< jfyu'. U U 'p . i u m e w .iM ' 1 1 1 ["1 ' J -JJI M" '* *' P P O O U C E D BV FORD General Hydraulic Broke Service 12-01-19 . r,ne through its a p p r o p r i a t e rib hed hole I * L Assembly until the end of the line sticks m as far as the thickness of the ad ap ter ou* obo,uf or even with the b ar, depending an obove the Dar, 8 R elease tthhee ssccrreeww boaarr,, aun>du fmluar. e, -d line. Inspe Ct the flare for cracks or poor Flare form, and rep eat the process if the flare Is not correct. 9< R ep e a t Steps 3 through 6 a t the o p p o site wheel cylinder. , ^ t ,lX lr .1 <=~ " = - ""d d P'" - i j WU flare by tig h en in g the yoke screw o g S i! w ifh ie c o n d a d a p to r fitted , depending on the tool used. OVERHAUL WARNING: N 7 ^ ^ ^ : ndiUnhafl e T = ! n t linings. A sb es to injurious to health. Do not Di out dust with an d for this li" '- Z T J ho" . b . " fu ry u,.d .. - r iT - d U,, . h o . . , b . reeled bog for disposal. " " . . . . b i 1 """ I b r a k e HOSE R eplace a flexible b rak e hose if it show s signs of softening, cracking or other dam age. W h en installing a new b rak e hose, position the hose to avoid contact with other vemcle parts. r a x E ORUM - T v n C A L CO tS ID S3 S3 6500161 or an equivalent. ^ bloW;ng off with an. * etbioguludrniao,t=beeuremm,.o9vewd,.hV..ln ndd a d, ^industbrira,,l vtahc.uamin cleaner because ^ machining done L r 13 Rear Brake Drum Maximum inside ' iFlG. 13 Rea Surface Diameter Marking _ ' Locatimi-- E-100-- E-350, Bronco, and F .. 100--rF-350 . ,. - . _.. .' ' f properly exhaust ventilated equ.pmen . BRAKE DRUM REFINISHING s . . . .. . 2." t a * 1 * < . cleaned off the drum after the operahon " A badly scored, rough or ""' ' ^ f ' e r toThi lathe b. d - n d ,, turned o n . d - m ln.be. 1 ^ ny ^ . manufacturers instruction .) , arY to provide a material from the drum than mntact Brake drum , . smooth surface for the broke :shoe contact. Br<^ ^ ; maximum braking surface iaV' which exceed the brake drum (Fig. 13). Brake dr^ / s TM on the brake maximum braking surface diame , . . _ must be . drum, either through w ear uplaced. The maximum bra g meter drum (Fig. Reification which wJ0' 0n6 " inch) machining cut 2 . t w.ri i r S dr fdioT . 'S 'r . b b .-..10.030 inch) additional wear before reacbmg the .. discard diameter. ' . or rivets, or if the i 9 causing a brake k i;-* eliminate the wheel 3. To check rotor runout, f i > ^ adjusting nut. * ' ,a " d- 4. " b' k* J- - l ^ k e la th e to re-finish the disc b rak e v FRONT DISC BRAKES , .1. '..Remove the shoe and linings =s described . 12-24 Disc B r a k e s -- Light and Heavy uu y Sliding Caliper. ........... *v * -r v t T ir f o 1..b.i.r .b. p r o d u c e d by fo rd GENERAL UVORAULIC BRAKE SEHV1CE FLAT WASHER INSOIOS-' hub mut N 8 0 1 7 1A-5100 ni-M TEN MUT TO 2A 3-271 N-m n 10-2*00 LB-FTI A FT ER H U . IS SEATED USING S O C IA L H ua IN S T A L L TO O l lO A-A- 0 0 NOT US IMPACT W BN CH POR R EM O V A L OR IN S TA L LATION OP HUB N U T. AFTER NUT IS T n U O OEPORM NUT COLLAR INTO SLO T QP ORIv 5 h a PT USING TOOL AS IN- o' c I t EDIM TH IS PICURE. THE NUT MUST NOT SPLIT OR c r a c k whEMstaked ip NUT IS 5 P U T OR cracked APTER star. ING IT M UST BE REMOVED AMO REPLACED W ITH MEW. UNUSIO NUT. VIEW X REM OVING OR MOVING A HU NUT APTER STAKING REQ UIRES THE NUT BE r e p l a c e d w it h a new Ntrr - * s * THE STAKIN G TO O L CAN U FABRICATEDPRM** OUSTED HAROENED CHISEL. THE CORRECT RADIUS ON THE C H ISEL TIP w il l p r e v e n t im p r o p er STAKING. 0 0 NOT AT TEM PT TO ST A K E WITH A .SHARP EDGED TOOL. h '-LL-- - : 12-01-25 RADIUS I.S UM i .23 1.08 IN i on ! C-J CO Csl ID K) S3 FABRICATE TOOL _ AJAMjyf . . hoibt- -F1G.1.1 Hub Nut Installation Refer t'o Sect*io-onn 1111--11A2 rFrruont Hubs for nut tightening procedure. ...,, ..- Drum Brakes `' ' ' . .-1 Remove wheel and tire assembly and drum " assembly from spindle. . . S S f f .S L iS f n iS w ^ , ' right or left wheel turns. - 6:-fflding of' .rake pedal (common on toft-front applications! mast fa avoided. - from backing plates and lnt.no, ol me brake. drums. - . .......: tAPAnwiNt?- Dust and dirt conditions present on 7. The heel and hr. biiw w* theTwh'eel>,rtire and'drum^can he removed as a . -.unit. . y 8. Do not attem pttoctoa^or J*lin- . soaked h'cke 'mmPk- TM e" Cmus , Be rep,aced K c m llm e axie sets and the rolor h.akina son taces wiped clean. 9. Do not lubricate caliper slide pins. ^^r^ 1^ ' an ''u p Sa ^ Up P e 'llp'p ' from brake system. * h ^ d k t 9 eB(S ^ r . llailtealth haVrd man mad^airborne by cleaning with compressed air. ... . deaner is availabl ^ aQnd dirt (rom tha vacuum S e T s l i o e l d h i disposed ol in a manner that prevents dust exposure. . . ventilated equipment. . fa '' ~ s ty y / f a : i^ - fa .. P R O D U C E D BY F O R D 12- 01-08 General Bralce Service 12- 01-08 brake tubing replacement of the retracting and be 9i.nsOoenctc(dIolaonrnw? eacraloirpedramtaygpee. disc hmoeldn-ddeodw. nOvseprrhinegastedis ssptrrionnggslylosreectonmeir comu eas sdecatmioangeodf, thethebraekneurteubisnegctbioen _ r brakes, the caliper assembly must be removed irom the spindle prior to re pull and could cause ihe new lining to wear prematurely, if they are not re should be replaced with tubing of the moval of the shoe and lining assem placed. If the brake drum* are heat same type. sue. shape and length'. Copper tubing should not be used in a blies. ' ,, 10. On floating caliper type disc spotted, indicating a overheated con dition. they should be replaced. hvdraulic system. When bending brake tubing to fit underbody or rear brakes the calipers must not be interchaneed from one side to the other. 5. If the vehicle has 30.000 or more miles of operation on the brake lin axle contours, be careful not to kink or crack the tube. When the caliper is installed on its proper anchor plate and spindle, the ings or signs of ovemeating are pres All brake tubing should be double bleeder sere *.11 point to the rear of ent when relimne brakes, the wheel cylinders should be disassembled and flared properly to provide good leak the vehicle. If a caliper is installed on inspected for wear and entrance of proof connections. Clean the brake the wrone side of the vehicle, it is not dirt into the cylinder. The cylinder tubing by Mushing with clean brake possible To bleed the system properly. cups should be replaced, thus avoiding 11. Do not attempt to clean or future problems. fluid before installation. When connecting a tube to a hose, tube connector, or brake cylinder, restore oil or grease soaked brake lin ings. When contaminated linings are 6. Inspect all other brake parts and tighten the tube fitting nut to speci found, brake linings must be replaced replace any that are worn or dam fied torque with Milbar Tool 1112 in complete axle sets., aged. .. 7. Inspect the brake drum and. vl 144 or equivalent. A[ J ! DRUM BRAKES necessary, refinish. Refer to Part 12-02 for refinishing. 1. Remove the wheel from the drum, and remove the drum as out- . 'lined in Part 12-02. , . 2. Brush all dust from the backing plates and interior of the brake drums.. . . , . .. " 3:"lnspect the brake shoes for ex cessive lining wear or shoe damage. If the lining is worn within 1/3- inch of the rivet' heads'or if the shoes are damaged, they must be replaced. Re place any lining that had ..been con taminated with oik . grease or brake fluid. Replace lining m axle sets. Prior to replacement of lining, " e drum diameter should be checked to determine if oversize linings must be . installed. '. , 4. Check the condition of braie shoes, retracting springs, hold-down springs, and drum for signs o ov erheating. if the shoes have a slight ui... indicating overheating. BRAKE BOOSTER Check the booster operation as noted in Part 12-01. Power Brake Functional Test. If the brake booster is damaged or inoperative replace it with a new booster. The brake boost- HYDRAUL1C LINES - Steel tubing is used throughout the brake system with the exception of -the flexible hoses at the front wheels and at the rear axle housing brake tube connection. . Always bleed the applicable pn- marv or secondary brake system after primary or secondary brake system hose or line replacement. Ceniral.zc the pressure difleremial valve after bleeding the system. BRAKE HOSE ' ' A flexible brake hose should be re placed if it shows signs of softening. cracking, or other damage. When installing a new front brake hose, position the hose to avoid con tact with other cnassis parts. Place a new copper gasket over the hose fit ting and thread the hose assembly mo the front wheel cylinder. Engagethe opposite end of the hose to the bracket on the frame. Install the hor seshoe-type- retaining clip, and con-, neci the tube to the hose with the tube Titling nut. ' ' A rear brake huse should be in stalled so that it does not touch the muffler outlet pipe or shock absorber. Thread the hose into the rear brake lube connector. Engage the front end of the hose to the bracket on the frame. Install the horseshoe-type re taining clip, and connect the tube to the ho'se with the tube fitting nut. 005233 PRODUCED BY FORD 005234 12-0 >-29 General Hydraulic Brake Service Clean 11 p a rti in el=a `prpyl llcohol, and inapcct the parts for chipping, excessive wear or damage. Wben using * aster cyliader repair VJt, Iratall all the parti supplied. Be sure that all recesses, openings and internal passages re opal and clean. Place all p a rti on a clean pan or paper. Inspect the master cylinder bore for ' jigns of etching, pitting, scoring or rust. If necessary to hooe the master cylinder bore to repair damage, do not exceed allowable hone specifications- . Assembly . Dip all p arts except the m ' cylinder body in clean brake fluid (ESA-M6C25-A.) Ford P art No. C6AZ-19542-A or DOT-3 equivalent. j_ C a re fu lly in s e rt th e c o m p le te secondary piston and return spring assembly in the master cylinder bore (Fig. 23). " 3. Install the primary piston assembly m , the master cylinder bore. '+. Depress the primary piston and install the snap ring in the cylinder bore groove. . ' 3. Install the push rod, boot and retainer . on the push rod. if so equipped. Install the push rod assembly into the prim ary piston. M ake sure the re ta in e r la properly seated and holding the push rod securely. 6. Position the inner end of the push rod boot (if so equipped) in the master cylinder body retaining groove. 7 Install the secondary piston stop bolt. ' if used, with an O-nng if screw is on bottom outside of master cylinder .casting. t g. In s ta ll th e bleed screw (if so equipped). Install the gasket (diaphragm) in the master cylinder filler cover, Position the gasket as shown in Fig. 23. M ake aure the gxsket is securely seated. 12-01-29 Install the cover and gasket on the master cylinder and secure the cover into position with the retainer. Hun-c FIG. 2* Removing 5nap Ring-- Typical CLEANING AND INSPECTION DISC BRAKES 1. Remove the wheel and tire from the > hub and rotor. 2. Inspect brake shoes and lining for ' wear If the lining is worn to within - ' l/j- inch f the shoe, replace all (4) shoe and lining assemblies (complete . sxle set) oh front or rear wheels as appropriate. 3. Visually check the caliper. If the ' calipa housing is leaking, it should be replaced. If a seal is leaking, the calipa must be disassembled and new sods installed. If a piston is seized in the bore, a new caliper housing is .required- , Refer to P a rt 12-20 for diae orak* rotor resurfacing procedure.... *>' Front wheel bearing end pjy j 1 c ritic a l and m ust be w ithin specifications. 5. Be sure the vehicle is centered on the hoist before servicing any front end components, to'avoid bending or damaging the rotor splash shield on full right or left wheel turns. 6. Riding of the brake pedal (common on left-foot applications) must be avoided during vehicle operation. 7. The wheel and tire must be removed separately from the brake rotor, unlike drum brakes where the wheel, tire and drum can be removed aa a unit. .. i. Do not attempt to clean or restore ou or grease-soaked brake linings. When * ' 'contaminated linings are found, brake linings must be replaced in complete axle sets. ' DISC BRAKE SERVICE . PRECAUTIONS ' ` ' - l:-. Grease or any other foreign material must be kept ofT the linings surfaces of the rotor, and external surfaces of the hub during service operations. In handling the rotor and caliper issemblies, avoid deformation of the brake rotor and nicking or scratching of brake linings. 2. If a calipa piston is removed for any ` reason, the piston seal must be ' replaced. - ' ' ' ' ' . 3. During removal and installation of a wheel assembly, exercise care not to ' interfere with and damage the calipa splash shield or the bleeder screw fitting. DRUM BRAKES. 1. Remove the wheel from the drum, and remove the drum as outlined in Pan 12-02. 2. Use an industrial type vacuum cleaner to remove all dust from th backing plates and interior of the brake drums. , . 3. Inspect the brake shoes for cxc" s'''e limn* wear or shoe damage. If the lining Is worn within 1/32 inch of the rivet heads or if the shoes are dam aged, .they m ust be replaced. ' Replace any lining that haa been contam inated with oil. grease or brake fluid. Replace lining in axle sets. Prior to replacement of lining, the drum diameter should be checked to determine that the brake drum braking surface diameter is within specification. If the braking surface diameter exceeds specification, the drum must be replaced. 4. Check the condition of brake shoes, retracting springs, hold-down springs, and drum for signs of overheating. If the shoes have a slight blue coloring, indicating overheating, the retracting and hold-down springs should be replaced. O verheated aprings lose their pull and could cause the new lining to ear prematurely, if not replaced. If the brake drums are heat spotted, indicting an " T re a te d condition, they should he replaced. 3. Inspect all other brake parts and replace any th at are worn or . damaged.- 1 '-. ' .. Inspect the b rake drum and. ii '' r' necessary, refinish. th e maximum inside braking surface diameter is shown on each brake drum (Fig. 23). If the maximum inside braking surface diameter shown on the drum is exceeded e ith e r by wear o r refinishing, the drum must be ` replaced. Refer to Part 12-02. for reftnishing. BRAKE BOOSTER ` ' Check the booster operation as noted andel- Power Brake Functional Test. If the brake booster is dam aged or nvr renlace it with a new booster. PR O D U C E D BY FORD .1 . I T- ' S- i fI-: ' . 12-01-22 G en eral Hydraulic B rake Service '7 ^ 1 2-01.^ ' ' 8. Remove (he line and inspect the flare, for cracks or poor flare form. If the flare ts not correct, cut it off and repeat the process,- ' The finished flare must be square with the line, free of cracks and have a smooth mating surface to ensure a leakproof connection. Flaring a Line (Flaring-Bar Type| Refer to Ftp- 13 and 17 1. Cut off and straighten the required length of line. (A line cutting tool will _ simplify making a dean and square cut). 2. Square off the ends of the line with a file, and chamfer the end of the line to be flared- 3. Insert the line through its appropriateribbed hole in the bar assembly until . ' the end of the line sucks out about aa . far as the thickness of the adaptor above the bar, or even with the bar, depending on the tool used. / - ' 4 Fit the adaptor onto the line and slide the bar into the yoke. Lock the bar in position with the line beneath the yoke screw. 5. Form the single flare by tightening the yoke screw securely. 6. Release the screw and remove the adaptor. 7. Form the double flare by tightening the yoke screw again, with second adaptor fitted, depending on the toot used. 8. Release the screw bar, and flared line. Inspect the flare for cracks or poor flare form, and repeat the process if the flare is not correct. 9. Repeat Steps 3 through 6 at .the * opposite wheel cylinder. Type) ' BRAKE HOSE Replace a flexible brake hose if . shows signs of softening, cracking or other damage. : " When installing a new brake hox. position the hose to avoid contact r-',- other vehicle parts. . REMOVAL AND INSTALLATION BRAKE DRUM . . All V ehicles th ru 9 0 0 0 Series - Use the following service procedures for both hydraulic and air brakes. Since . the F-100 thru F-3S0. E-100-E-350 and Bronco rear drums, and the P-500 (front and rear) procedures apply to hydraulic brakes only; they are covered in Part 12- :-.C52-.:... Y.f 4. Remove the front w heel-to-hub retaining nuts (or rim and tire attaching nuts). Remove the wheel - (or rim and tire) from the hub and drum. 3. Remove the brake drum, retainers and _ '....attaching boils, screws or bolts and . nuts. . " 6. Remove the brake drum from .the,.. ' ` Sub. ' . . ' FRONT BRAKE DRUM . ' . 1. Raise the vehicle until the tire clears the floor and remove the wheel and tire from the hub. Loosen the brake shoe adjusting screw until the shoes no longer touch the brake drum. Remove the grease cap and the gasket 7. Check the drum for'damage'or wear, and repair or replace if necessary. If a new drum will be installed, be sure to remove the protective coating with degreaser. Install new grease retainer seals whenever a wheel and huh Is removed. (if equipped) from the hub. 8. Place the brake drum to the hub and 2. Ou vehicles with 9.000 lb front axles install the retainers and retaining _nd hydraulic-brakes, remove th e . - - -bolts, screws, or beu * and n:1rx. locknut, locking ring, dimpled washer ajjd adjusting nut. On all other a.tin . remove the cotter pin, adjusting nut and flat washer from the spindle. 3. Remove the outer bearing cone and roller assembly. Pull the hub and drum assembly off the wheel spindle. 9. Install the hub and drum on the wheel spindle. Keep the hub centered on the spindle to prevent damage to the . grease retainer or the spindle threads. 10. On vehicles with 9,000 lb front axles and hydraulic brakes install the outer bearing cone and roller assembly, and the bearing adjusting nut. On til other axle., install the outer bearing .. cone and roller and flat washer on Ihe spindle. Install the adjusting nuL . "Tl.Tnstall the wheel and'tire on the hub ... Then install the clamps (if applicable! , and the wheel stud nuts.;... .. j -- 12. While routing the wheel, tighten the^ adjusting nut to specification. Adjust wheel bearings as described in Group .. 11. - . . 13. On vehicles with 9000 lb front ask and hydraulic brakes, install the dim pled washer with the dimple indexed in one of the holes in the adjusting nut. Install the locking ring lock nut and tighten to specificinoe. Bend the locking ring over a flat of the lock nut. 14. Install the gasket (If equipped) u d the grease cap. and tighten the wn stud nuts to specification. Install the hub cap (if equipped), and id just brakes as described in this Part- OVERHAUL An industrial type vacuum cleaner in place of compressed ur, is recommended to remove any dust and dirt present on brake linings, pads, rotors and drums ect, when performing wheel brake repairs. Also, any m a c h i n i n g done on brake linings or pads should be done using properly exhaust ventilated equipment. BRAKE DRUM REF1N1SH1NG E-100--E-3SQ, F-100-- F-350, U-100 Minor scores on a brake drum can be removed with fine emmy doth, provided the emery is thoroughly cleaned off the drum after the opentian. A badly scored, rough, or out-of round drum should be ground or turned _ on a drum lathe. Do not remove a J mote material from the drum necessary to provide l smooth sur`a" a the brake shoe contact. Brake "ru ^ maximum braking surface diaele* shown on each brake drum (Fig- Brake drums which exceed the ^ braking surface diameter shown on 005235 BV F O d D r ^ . - ^ l tiydraulic-Brate Sgfvia- installed. If a piston is seiied in the bore, 0 n=w . ... ..c a lip e r- W > n g ^ [*q<l>r~L " _ ' _ . R efer to Pr aarnt 12-20 ,A for dite brake ^ rot resurfacing procedure. ' ' DISC BRAKE SERVICE PRECAUTIONS '1. Grease or any other . off the surfaces of the nuo g,,d external . service operations. In J assemblies, avoid i j If the brake drums or heat s p o t t e d , in d ica tin g an o v er h e a ted .condition' th ey Should be replaced. Inspect all other brake parts and replace ony that are worn or damaged; ' Insoect the brake drum and, if necessary , finish. ITnhsepemctaximum insijae bDrraakminnga surface diameter U shown on each brake drumi (Fig. 33). the ,s snow . . . u._t,:na surface diameter shown on . T T :'X - d i d b y , .sfinbhlng. r[ CefIilnlllivsihingJ . . . . b rlaakme: Bo O O S T E wR ...- .. w - 1 - 2.. c b k * . bo.. K r lTM ;V b TM ? = ,"X = ; " I Z t ' Z ' ' X ' . " 1* ^ ~ .l~_bl.-d.r u ; : p; ^ T r d 5. b V X X X ' s" ' X X right or left wheel turns. x='" h `hi' ld " ., r 6. " X t sk X 's .73: -m - 7. ^^^aSOSpSt i J =V d.Um 10 b . . 6 . Bo X r r < ; J ' "X ,, X T = X o K X L i t t f b r X ' iV .. ... b. ^ g L 'S L Z t & s x . * - * ' - drum brakes rbinrca'lkurde ixnbgoTotshte.e,rchecpk7 . vmal,vue. . * . . .. . "-r. 4 BRAKE TUBING s::^:;pr`Vr^rixvs ( b- brake tubing becomes damaged, |f a section of th b rspiaced with tubing of the the en re sec ion shouJ * r ^ Coppflf tubing b,, " S . b" c U w " > > " " " = k ,ht " b' ' hyTdUKrMauUil.iivc* u--n-e--s- ,, W .d n . - opp|ito b l..Pri .y A lw a y s b le e s y s t e m a f t e r p rim a ry or s e c o n d a r y b^ak Y, h o ie Qr replacement.- - S r S h . p ,. 1 d(-- " '* bl" J:"5. the system. &&3SSS3S 2- 3. Inspect the brake * * ^ . *=' * ' " ^ g u S they must be replaced Repla any ^ ^ been contaminated with o . 9 ^ ,acemen, 0f Replace lining m " , shou|d be checked to 0 or equivalent. ;,BS b r a k e h o s e ' .. . . ,, . . 1 brake hose should be replaced if it * ovi , - = k 3 . 0, o*=r d . = , . . - d~ " 4. ^ T = " 'd1;,o. , bt . ^ springs, V hU s have a slight blue h o ld -d o w n ip n n g * h' uld h , ^ eou,d O verheated ^ .m a tu r e ly , if cause the new lining to w ear P gasket over hose wh= e , cy|lnder or caliper- assembly into * = front whee^ ^ q c per Fairrnont/Iephyr r cnQaae the opposite end of th gasket and is reusable. ^ white sthpe on hose to the bracket on he . )njtQ|| th. * w i S n ^ - s t r x ,, ,, .b. b . -i " * 005236 'r' h u i v l O B Y F O R D General H vd ro u lic Brake Service^ 12- 01-20 12-01-20 OVERHAUL ,, -A nr nil contam ination th a t is causing a brake 5 re piece all four shoe a n d lining assemblies. , A A\r<t from b roke assemblies Removal of dus* an Rotunda brake vacuum should be done by 0US' 9j _ braRe parts washer (model (model 24-0009) or R o - d r^ emb!y dus, end dirt 650016) or on -,ther blowing off with an should not be removed y ^ induitria| vacuum a ir gun or v a c u u m . n g ^ i t ^ h a io rd from breathing m cleaner because ^ | s0 any machining done asbestos dust may should be done using properly r,hTM ." is . s **"d b r a k e d r u m r efin ish in g d" " hr s 1 " end ^ Then check^to^be^sure the rotor con still be rotated. _. (_i indicator to the spindle so the stylus G am p a d 1 nDproxim ately one inch from the contacts the r r PP rotor and ta he an indicator 0Utdr n a 9 l, rh J reading e x c e e d s ,254m m (0.010 ; ^ - a , lateral r u n o . w ^ ^ ^ r ^ , s o n ,W?ar T h e T o llo w in g re q u ire m e n ts must be met X n re-surfacing^' disc b ra k e rotors t r than Ho more t ay be m=h,n L t l l o c -- in ..TM . .TM -) 508mm (0 .0 2 0 inch) of material ,, off e a c h surface |A ond th ic k n e s s foils below the miTM I 'T w ^ y fine emery clo , P ^ operation. , j ,,K the drum after rne cleaned oft t 011,.0f.round drum should A badly scored, rough, or (Refer to the lathe be ground^or turned ^ Q n o t " remove any more manufacturers instruct: ^ , necessary to provide a material from the d ^ h smooth surface for the Dra eonloCf. Brake drum is shown on each maximum braking sur ace ^ which exceed the brake drum (Fig- " , a , , shown on the brake 3, ,Smmn 25 INCHI .0 .0 0 -0 .5 O 8 n .r r 10 0 20 IN C H ' ach minimum OVEBALU THICKNESS 23 9 2mm 11.180 INCHI " m"1' ,i p ' J4 39mm (0 98 INCH) 0 00 CLSOamm 10.020 INC*-- MINtMUMTHOIVCEKRNAELSLS 28 4imm' 11.120 tNCHi drum, either throug KraRina surface dia m eter replaced. The . specification, which is sh on och brake drum (Fig. machining cut 13). allows for a U J V ^ m e t e r plus 762mm . o(0v.e0r30theincahn)gai ndadli t ino0nTMa l "w 'e a r before oei reaching . the drum ' discard diameter. . . . , *. - F.2S0 i* * * ANO F 0 0 O V E 6800 CVVI I* X 21 E 250-M0 10.22rHm 11.190 INCHI - r r 0.00 O.SOBmm 10.020 NCMI minimum overall thickness M.120 INCH POOO *xw *7 0 0 C V Trt WITH POWER B R A K E ! FIG. 13 Location-- E -l00--E-350, Bronco, and8 FF- 100-- F-3 5 0 -----1-*^ F-IOOIM I* ANO O NCO . F 2S0I 14 FJ50 i KC 6RWJB" AItts| H-Ort'16 * |txcEPT F.,00 4*00/4200 OWE WITHrvr. FIG. 14 Disc Broke Rotor Service Umiti The finished broking surf c" ^ h?Q QQ^inch); b efta. 8 f " f 0 i n - I0.0M lateral runout must -to. ^ wrfaee r,n,sh m . be 16 to 80 micro 1. 1 2 - 2 4 Disc B r a k e s Sliding Caliper 2. Measure the thickne brake lining. If the >be a siembly is less cb o.e lb. beating plot. rV ." . " " `.S I ' i b e a rin g . = d ""* ' u l i e . i t F-- 1 Drtv) fo P 'or scof^ 5. Cheat the rntnr . ' " ' T f f t e '. o t n T .r U a a " ' 1 PRO DUCED BV FORD g en er a l hydraulic BRAKE sRV1C_ 12-01-27 fX # I2'01 hiria is centered on hoist beforei s: er Be =s>u--r-e--- . o=n'te e'n*nddccoommppoonneenntst,s,totoaavvooiuidbten- wtcinQ any front en shield on r l n0o r n 9 rotor sptastt sNeld oo lull i,h or L it wheel turns. , Check condition of brake shoes, retracting spr- C h lr io w n springs, and drum for signs of mg, holddo bave a slight blue color- r rS a ng o v e r l i n g . retracing end bold ing, indicau a renlaced. Overheated ,,own aP""9 J (0U" " gTould cause new ,.n- s pltiiccation'sr) srnu, s?i s = lS operation : t . ? M f A 's r s r " ^ r i n i o S S 'in .r n coo oo recover, as a 5. Refer to part 11-15, for hub nut tightening pro cedure. unit. & Do not attem pt to c l e a r ^ J " torei oil ^ & soaked b r a ^ . " J X f l E TM s t be replaCed Incomplete axle sets and the rotor braking sur laces wiped clean. , Do not lubricate caliper slide pins. from brake system. . Drum Brakes ... - 1. Remove wheel, tire and drum assembly-.cm. spindle. . . .' ' 2. use an Industrial vacuurr] ^ ^ Z T o T S I dust from backing plates a brake drums. ' ` . u . u Hust from brake linings .. WARNING: Never ^ a> r be niurious to JCibestos dust when ir |in8. A Mcuum ceaner.eqi^ppU tor this Brake Booster Check booster operajon Brake Functional Test I bra e ^ ^ boosti!r. The s r K - is & <">- " semb,>' eluding the check valve. . Brake Tubing ^ ' ' ' hrake tubing becomes damaged. If a section of brake | ed with tubing of the entire section shouid b length> Copper tub- the same type. s,ze' . j 5 hydraulic system. When Hydraulic Lines Double wall Steel ^ S r ^ - w S e ., Always bleed brake system al e r ,,tacement. Centralis S S I . S r - U ' : ; ; ,, e iSter bleeding system. diiposal. - - - '' All brake tubing shTMld ce S o - T ' - M p T CLan 1 inapeo, brake w3m or shoe damage. It lining riveted lin ' within 1/32 inch of the rive b 0p bonded ings or within 0.060 In? ^ ` thRVcJace an^lning linings, they must replaced Replace any - that has been contaminated with o.Lgre^,^ ^ before installation. MWiruld . . When connecting a tubejo J s0preciV,eftorqYue wit'h he D31L-600-A Inch-pound brake fluid. Replace lining eter should be torque wrench. ^ replacement of lining, dru drumbraking checked to determine that . npcif,cations. If surface diam eter la ' ' " ' " A V . p f a S l c a braking surface diameter exceeds P tlon, drum must be replaced. ^ ! i' 005238 p r o d u c e D BY F p <m o v a i a n d i nst a ll a ti on _ apply > hydraulic brakes. . * ^ Mver inhale dust from broke lining*- w U H1NG: N inhaled can be injunou. to A >!o* =iu ` b| out dust with an air line. A ^ ^ " " equipped for this purpose, brush -- be carefully used to rem ove any '* ^ d" lt should b e c o n ta in e d ,n a s e a le d b ag #*+* * n ' . M ivposal. SPOKE WHEELS the vehicle until the tire clears the floor and ,`m I sa fe ty s ta n d s . R em ove the tire a n d r,m ' Wv bv rem oving the clam ps and nut. J a . .< .?<* " d d," m o" OTbl, 1 nvina the nuts, bolts a n d w ashers. _ ` C U -He drum for ^ ^ 1 ^ S * ^ ^ ^ X X e ^ : a t i n g w , t h a d e g r : serQnd NOTE: R-Place the ^ " ^ i ^ ^ ^ . h i c l . ' ,, o n c e 'R e p la c e cast drums with cast drums. c n tr if u s e drum s only w ith centrifuse^ , .> -drums.. , - - * . j T!/*Ufr^n 2 Assemble the cast spoke spider and drum assembly ' 7o the front or rear axle. Adjust the wheel bearings and the axle shaft installation, if necessary, per the appropriate Section in G roup 11. j Install the tire and w heel a sse m a ly on the cast ' spoke wheel. Refer to Section 11-01, W heels, Rims an d Tires for the procedure. 4 Tighten the front and rear wheel clam ps to 299-352 N -m (220-260 ft-lbs). DISC WHEELS-- OUTBOARD MOUNTED DRUMS Removal , 1 Raise the vehicle until the tire clears the floor and ' install safety stands. Remove the nuts retaining the tire and w heel assembly to the hub [Fig. 6). 2. Remove the drum from the hub. T Check the drum for d am age or w ear and repair or 3` I re as necessary. If a new drum is mstolled, be ft. - a "k degreaser. ' NOTE- Replace drums with drums of the,sam e ty p e .. ' ' F a i l u r e .o d a so will a ffe c t v eh icle track and l - n r. Reoiace cast drums only with cast t Z . p i . d; y - r ! T C ' h, - - -centrifuse drums. , Check w heel grease seals for le a k a g e . If the hub . is! rem oved from the axle, install new wheel g rease seals. ` ... f'O. 4 Brake Drum Mounting* 005239 ee.jie a '?" PQ ii PRO D U CE D BY FOR  b*I S r '" General Hydraulic Brake Service 12-01-19 d= P '"di"9 " n i irrew bar, and flared line. Inspect the 8' t X t d s or poor flare for., and repeat the process if the flare is not correct. , . Rapna, Steps 3 tktPPSh 4 a . the o p p - 'e -heel cylinder. , b " .t . k^ ' ,is,' ' " i" s * ,o ie t x * -- - " j * ' dap,r ^ . u bv tighening the yoke screw 7. ^ . ^ t ' c ' d 4 <i=d. d . P ." d '" 9 rise tool used. ____________ BRAKE h o s e Replace e H e,M e b , . k . h a s , 1 . s h e - 8 < softening, cracking or other dam g w hen Installing n - broke h a . * f0 avoid contact with other vehicle r ort . OVERHAUL v,nU dust from brako WARNING: N e V ' ^ h e n ,, h a le d can b e linings. A sb es os dus dus, with an Injurious to h ealth . De " equipped far this sir line. A - CoUrUr^ _ C ^ C ld b V carefully used to ^ r v V = n y U,l : t - Any dust should be contained " ,, sealed bag for disposal. Removal a . t o . . should be done by using washer Imodel S . 1 34.0009) or '" '"" t ^ m b l y *> * > .- A50016) or an equivalen . ^ y ov,ing 0ff with an . s3h,rougludn noortvabceuurmeTingv^Wi. h o ssttaannddadrd^industrial tvha5cugumin cleaner because a . any machining done aibcsto* dust may should be done using properly on brake linings or pa machining : ihaust ventilated equipment Also J using don. on brake linings or pads should o . - h au st ventilated equ.pment. BRAKE. DRUM REFIN15HING . , , n ,, Dralro Drum Maximum Inside F'G- 1 L aW ng Surf Diameter Marking Location-- E-l00-- E-350, Bronco, and F- 00-- f -350 . . 7 `' ' ' ' . 2. - f c * . lining < **>"i Pl P rP fa I! & ,he backing plot, tleoned oH lb . d~m a * . I ' " " i -u rs* rtut-af-rouna drum snouic bve /ground or turned on iad ruu m _l_a_the. (Rmefaeyr.toatnhye lmatohree manufacturers instructions.) neCeJsary to provide a material from the jhoe cont2 t . Brake drum . smooth surface for the bra shown on each . mcsimum br^ " g ^ ^ T r ^ m s which exceed the broke drum (Fig. *i* Bra1;. ,Lnwn on the brake ^ximum braking surface ^ame must be ^KlflMtion, -hich o m " ch) mochmii.9 =" ' 13), allows for a l.52mm v tef njus .762mm ever the original nominal drum h;ng hie drum- 10.030 inch) additional wear before re 9 . Sscard diameter. . niOMT DISC BRAKES .: 1. ' Remove the shoe and linings as d -crib ed in. Section ' . . 12-24 Disc Brakes-- Light and Heavy Uury Sliding Caliper. x^sss:^^. 3. To check rotorayUb Uightr= iing'riT idjusting nut. B r f b ? i .b. TM b` - r ,* reading. If ,h inch) total lateral ^ . Within a six inch radius on 0 B the d!sc brake J l S r S l K i n g requirements must be met w hen S u r f a c in g disc brake rotors. ,. . nL . ta the to re-finish the disc brake * a n a ..TM ,- "' - ' . ' No ,, ,, h . J o s ; ' << , b . " ^ ' ^ " " hickn.! folli b d a - * ' 005240 -- r n u U C E D BY 12-01-25 3. . Hub Nut installation ' ' . 11 1 ? Front Hubs for nut Rater <o Section I V . F'" , tightening procedure- . Be sum vedicje Is Djrruuumi Bk-riia*k'e--s hPPl and tire a sse m b ly and drum assem bly^from spindle. \ j . R e m o v e d ru m a s s e m TM , >,0TM ^ T d u s " . right or left Wheel turns. ` . . brake pedal (common on left- ron / ' 6' muet be avoided. .. drums. ` - . .. WARNING: Oust nd t n ^ o t i s i n d 5 d m m ^ m a y wheel brake asoamblies an - renresent a poten- ... . unit. s s s -*. -* `' ` a. do not attempt to c I e a ^ 9 ta minated Un . soaked Hrak9n h S e linings must be replaced ing3 ara ' ^ nd'lebsekts and the rotor braking su in complete axle sei=> . laces wiped clean. 9. Oo not lubricate caliper slide pies. . 5 f b t." S d L f S made 61 d e a " '" 8 with co m p ressed air. .......... ' b e . l b . e b . " S S S - S S S id. cleaned onW a " " - hls ,y5, ,,1 vacuum use with asbe**a through the Rotunda Dealer cleaner is ava; labi 8 s , and dirt from the vacuum S e T i l i o u l i b . - d i . 0O ,.d ol in a manne. ih prevents dust exposure. from brake system. ^ ... _ ventilated equipment 005241 PRODUCED BY F ORD 2ft. ' ( - L IB E R T Y M U TU A L , 21040 G m cnfirld n(|. H ,tro ll, M ichigan 48237 T ei. (313) 000-2325 Cooler Development D 1ci chip Presidents fj'r ' to Arhestos Dust December 29, ]975 l1r1: ..s* r~tls and clutch assemblies arc n.lo nf oshostns wMrh h-,c . .-..V,. 0 utcrlil prc^cf.,9 a f : J .0 5 1 1 " ` Y 11 CKCi'C2^va `--' r.ts over n It';;q p-rind of time. Luring th-1 la rt ) 1;*-` " vcr. altcnUcn lir.s h::;i in n i -d m, ti.: ('.-.vclor.ment of corccv- ( f t .j li-i rj crul oilier body areas follcwlng c;.| u-.iiro to acl.rslos dust Hn e.lcrc cnr.rcrnlng the potential health karenl for persons exposed to asbestos < - l i . ] 1. 1 servicing of rale-.- vehicle h v l c I rlmr.l, assemblies was issued 1 - I.-1 i. . .a1 Ii.s 1 1 tu1 e for Dcctir'aUr.n-l ' v ni.i liralUi on August 0, 1975. i * u i iV.r eases of rei\-r.i.nll;:l ir.l ( " {il 'ns ilio were empiuyed h. i' ' , ' J ' - v1^ ' `a >i'e!c_scrvic1un. Ibis i,n. . i.r (..i.f...r..n..i...e..e.r. Imn uthlBe Cr.i;-:.,.;LL|aa,.iiec ` 1 > <n_ci sto ....eli Ct iis.e 1 in lf)rh n i - 11;3 in the general norulo"' u ' " 2 c; `r lQS K-.+ers h.-.:l tiri- .1? (1 ,,ut 0? 20) had died of alCG c-t'fre Inno m ire r; and an asbestos worker i. ..j S...W..LS is 50 tires more likely to get. Itiirj cancer. i.>. full Client of asbestos-related disease In birbe servicing personnel 1s not f V. Y ! : f `.l1s crc;,f1 lK^ ncvn' b=fo>- l r ' " fVtlr.TaUcally studied. Excessive .-i. c--- c..cations r.sasurcd at operai 1r.ir-, r"'li rs l)1:::-cut r.f cnte-cbllo circa . . .. .. asce, li e s , griming of used true I: hrnln linings, bevelling of nei truck' .. . 1 n..1i/;> cud arcing of new auto Lir.be lining:, together ulti) ir.ssjtlrl l'ai f - 1-cns so employed, affirms the necessity for effectively controlling f'VU5n5 v;` d0 not havo cc:nn',G^c Information on linv/ much exposure, 1 f any, can li , : Qnds? 1t 1s important to eliminate exposures whenever possible and., r.iinuuc those uni eli camicie be eliminated. ' ttcuunmciiiJcd practices are listed belc.v. I'r.vr respirator: During brake servicing, an air purifying respirator, either slnnle use or with r^piuccal.lo particulate f l H c r s ( s ) , as app. "v.d .by the national' lust liuto for Cccupal t ml Safely and Health hlObll should I 0 r; i n .luring oil r.rnccd 1. es st:il.1i.:i with Ibe if,.oval of Hie i.brels ; i.l lulurllr.g rcas::..lily. Ir.irir.g can- u.l clnli h servicing, sur.h a r..-spliatnr :l.<nli| la din lug r.inval ard clrsUi.g of tlia clutch, pressure: plebe ard i-Mir,lug .ifsrcrbly ar.d during in-jtuiiQiiUti of tha new clulcli assembly. IM*; shuuld also Includo ouy arcing or riveting operations. 002809 uotrt-n m utual insurance company u d eh ty M|,T,lHMT.Vrir-M,A!!.\.nMH, r * N'f * `" `K"TY UFE EQUAL OPruKXUN TY EM1MJIV LI13 )Q COMPANY OP BOSTu. PRODUCED BY FORD The sticky note shown below was written by Barry Castleman and attached to the page immediately following this one along the right margin at the spot marked on the next page with an INDUSTRIAL HIGIENE AUDIT OF OHIO TRUCK PLANT 6 - 8 June I 983 An in d u s tr ia l hygiene audit was conducted a t Ohio Truck Plant on June 6- 8, 1983. The purpose o f t h is au d it was to evalu ate environmental co n d itio n s, work p r a c tic e s, and p ro cesses in the plant th at could ad versely a f fe c t employee health or con trib u te to worker discom fort. Mrs. Nancy Lutz, Plant S a fety Engineer, very cooperatively a ssiste d during th is au d it. Elements o f the au d it included a p p raisal o f general plant and process v e n tila tio n , chemical handling p ractices, a ir q u a lity , hearing conservation, respiratory p rotection , corrosive chemical v isio n conservation p ra ctices, illum ination , skin p ro tectio n p r a c tic e s, sa n ita tio n , and heat s tr e ss p ro tectio n . O verall, the p la n t 's in d u str ia l hygiene programs are e x c e lle n t . Noteworthy are the lo c a l exhaust v e n tila tio n systems and con trol o f employee exposures to a ir borne contam inants. Exposures to overspray m ist and so lv e n t vapors in paint booths were co n tro lled as was exposure to fin e -w ir e welding fume and gases. D e fic ie n c ie s in some in d u s tr ia l hygiene programs were noted, however, and should receive attention. V en tila tio n Whereas o v e r a ll p lan t v e n tila tio n i s e x c e lle n t , a s lig h t n egative pressure con d ition e x i s t s . While in s ig n if ic a n t during warm months when large doors are open, t h is could be a problem during w inter lead in g to breathing zone a ir q u a lity problems. Plant engineering should assure p rovision o f s u f f ic ie n t makeup a ir to balance a l l supply and exhaust systems to w ith in ten percent o f each other. Sodium hydroxide m ist was extrem ely i r r i t a t in g to eyes and resp ira to ry tr a c t on the catwalk in the Caustic B u ild in g. The two sid e d raft lo c a l exhaust systems were in op erative a t the lye tank. These should be repaired and the ca u stic tank enclosure immediately designated a resp ira to ry p rotection area. A ll employees in t h is enclosure must wear r e sp ir a to r s approved fo r a lk a lin e m ists and must be included in a comprehensive re sp ir a to ry p ro tectio n program in compliance with OSHA standards and Company g u id e lin e s . The enclosure must be appropriately posted. A sbestos/Silica Sand b la s tin g o f brake drums a t the T r a ile r Maintenance Building presents p o te n tia l exposures to airborne a sb esto s fib e r and resp ira b le s i l i c a d u st. S te e l shot or g la ss beads should be considered as s u b s titu te s fo r s i l i c a to elim in ate r is k o f s i l i c o s i s . An a ir -su p p lie d abrasive b la s tin g helmet must be provided to con trol CXpOSUre to abu; stoa fib e r and d u st. A vacuum sweeper approved for asbestos fib e r should be purchased to remove r e sid u a l a sb esto s from truck t r a ile r brake drums before new brake shoes are i n s t a l le d . This vacuum sweeper should be made a v a ila b le to maintenance personnel who rep a ir and i n s t a l l new brakes in the h i- lo and fork truck v e h ic le maintenance area. Employees must be in stru cted not to use compressed a ir wands to blow r e sid u a l asb estos dust and fib e r o f f brake shoes and drums. Wet methods, vacuuming, r e sp ir a to ry p r o tec tio n , and v e n tila tio n must be used to con trol exposure to a s b e s to s . Brake maintenance employees should be on the a sb e sto s m edical su r v e illa n ce program. Illum ination Illu m in ation was m arginally acceptable in sev era l areas in the north end o f the p la n t. Much daytime illu m in a tio n in t h is area comes from s k y lig h ts . Illum ination i s considerably l e s s on the n igh t s h i f t . Steps should be in it ia t e d to clean and maintain e x is t in g lig h t in g fix tu r e s and to consider in s t a lla t io n o f ad d itio n a l Luminaire a . - PRODUCED BY FORD 012741 Ohio Truck Plant - 2- 6-8 June 1983 The area behind the lye tanks in the C austic B uilding was poorly illum inated, bince th ere are trip p in g hazards here and employees must p e r io d ic a lly enter t h is area o f corrosive and slip p e r y chem icals, b e tte r illu m in a tio n i s indicated Sanitation O verall p la n t sa n ita tio n and hygiene i s e x c e lle n t . No d e f ic ie n c ie s other than minor housekeeping were noted in c a f e t e r ia s , food preparation area s, canteens, lock er rooms, and w ash room s/toilets. The nuisance odor con d ition associated Wlt ^ g a r e t t e b u tts, food, w aste, and o i l discarded in to trenches around production equipment should be addressed by a p erio d ic maintenance cleaning sch ed u le. At the l e a s t , t h is con d ition i s v is u a lly u n a esth etic and i s an employee concern as expressed by the UAV H ealth and S a fety R epresentative. The food storage r e fr ig e r a to r in the Power House should be r e lo c a te d away from the chem ical storage area. F ree-standing water in the T ra iler Maintenance u ild in g should be co n tro lled to elim in a te a slip p in g hazard and harborage for mosquito and in s e c t la rv a e. F lyin g in s e c t s in the plant were not a problem, and we see no com pelling need fo r in s t a lla t io n o f more e le c tr o n ic bug k i l l e r s . Hearing Conservation There was in c o n s is te n t use o f hearing p r o tec to r s in designated hearing conserva t io n a r e a s. A ll employees must c o n s is te n tly wear approved muffs or plugs a t th ese lo c a t io n s . A v a r ie ty o f p ro tecto rs should be made a v a ila b le includ ing an approved earmuff and a t l e a s t two types o f earp lu gs. The Power House generator area should be designated a hearing conservation area and appropriately posted. Some metal f in is h e r s a t F-26, for example, were not wearing p r o te c tio n . They must c o n sta n tly use hearing p r o tec tio n equipment. The p ain t pot block house must be made a mandatory hearing conservation area and so p osted . Although exposures are b r ie f in t h is area, the n o ise in te n s ity i s extreme and poses a r isk of noise-induced hearing lo s s . Generally, hearing conservation areas should be more c le a r ly posted and d esign ated . Respiratory Protection Employees use appropriate and approved r e sp ir a to r s fo r a ir contaminants to which th ey are exposed; however, a serio u s d e fic ie n c y e x is t s because many do not use both strap s on the h a lf mask r e sp ir a to r s . This prevents an e f f e c t iv e fa c e -to - mask s e a l. This should be corrected by management enforcement and education and tr a in in g s e s s io n s . The p ain t residue removal area a t the Caustic Building ly e tanks must be design ated as "Respiratory P rotection Required". Written programs must be e s ta b lish e d for a l l re sp ir a to ry p ro tectio n areas in compliance w ith OSHA standards. Paint sprayers leave t h e ir r e sp ir a to rs on work surfaces adjacent to the b ooths. This must be corrected by providing an h ygienic storage area for each p a in ter 's respirator-. - -- - --* -- V ision Conservation Employees use inappropriate eye p r o tec tio n when handling or working near corro s iv e ch em icals. Eye p ro tectio n o f choice i s the chemical splash goggle which i s superior to a face s h ie ld for v is io n conservation . Employees must be in str u c ted to wear goggles where sp lash in g o f corrosive chem icals could occur. These areas should be so d esign ated . The chem ical eyewash fountain and shower in the C austic B uilding must be r e lo c a te d on the catwalk midway between both ly e ta n k s. Consideration should be given to i n s t a llin g an emergency eyewash fountain near BB-21, A-22 or A-21. I t must be emphasized th a t eyewash fountains are secondary to consistent use of splash goggles in v isio n conservation areas. Employees who handle strong a c id s, a l k a li e s , o x id iz e r s , corrosion in h ib ito r s , m icrob iocid es, and sc a le removers must wear sp lash go g g les. We see l i t t l e need fo r face s h ie ld s in chemical handling areas a t Ohio Truck P la n t. PRODUCED BY FORD 012742 Ohio Truck Plaut - 3- 6-8 June 1983 Air Q uality Other t han c a u s tic m ist a t the ly e t anks , no obvious a ir q u a lity problems were n o tic e d . I t i s a d v isa b le , however, to document exposures to solven t vapors in the p ain t k itc h e n . Arrangements w i l l be made to have p lan t personnel conduct t h is m onitoring t h is w inter when doors are c lo s e d . Air sampling i s a lso recom mended to document so lv e n t vapor exposures o f maintenance employees who clean p ain t sludge f i l t e r s in the basement a t C-37* Skin P rotection . There i s no evidence of ex c essiv e d erm a titis a t Ohio Truck P lan t in sp ite of p o te n tia l contact with a wide v a r ie ty o f dermal ir r it a n t s and s e n s it iz e r s . Several p a in t sprayers complained, however, th a t even two p a ir s o f green gloves do not prevent paint from p en etrating through to th e ir sk in . As a r e s u lt , they wash t h e ir hands w ith p ain t thinner a t the end o f the s h i f t . They b eliev e that white co tto n gloves which had been provided to them p r e v io u sly are superior to the presen t g lo v e s. The p lan t should s e le c t a glove to assure th at painters do not have to r e so r t to the use o f so lv e n ts to clean t h e ir hands. N on-silicone based b a r r ie r creams should a ls o be con sid ered . Although the so lv en t they use i s not ap preciab ly skin absorbed, i t can d is s o lv e p r o te c tiv e o i l s and lip id s from the skin and pave the way fo r an in d u s t r ia l derm atosis. Chemical Storage Greater a tte n tio n by means o f educating and tr a in in g l i f t truck operators i s required to assure th a t incom patible chem icals are not sto red to g eth er. For example, drums o f concentrated s u lfu r ic a cid were stored n ext to drums o f aqueous ammonia. Drums o f sodium n i t r i t e , a strong o x id iz e r , were stored next to read ily ox id iza b le m a te r ia ls. Inadvertent drum rupture as might occur during a f ir e or from im paling by or dropping from a fork truck could produce a chemical emission emergency. Ergonomics The BAO ergonomics task force should consid er the p o te n tia l fo r chronic hand/ w r ist m u scu losk eletal and n e u r o lo g ic a l trauma in se a le r a p p lic a tio n employees. Heat S tr e ss No s ig n if ic a n t heat s t r e s s f u l work environm ental con d ition s were observed. The I n d u str ia l Hygiene Services S e ctio n w i l l , a s requested, a s s i s t in implementing th ese recommended in d u s tr ia l hygiene programs a t Ohio Truck P lan t. In d u str ia l Hygiene & Toxicology Department Employee Health S erv ices jb PRODUCED BY FORD 012743